Submerged melt welding process and composition



Feb. 19, 1963 c. E. JACKSON SUBMERGED "MELT WELDING PROCESS AND COMPOSITION Filed on. 24. 1960 I 4 Sheets-Sheet 1 POWER SOURCE 022.52 moomhu BaO CONTENT-% A TTORNEV Feb. 19, 1963 c. E. JACKSON 3,073,193

SUBMERGED MELT WELDING PROCESS AND COMPOSITION Filed Oct. 24. 1960 4 Sheets-Sheet 2 FLUX ELECTRODE} MELTING RATE- L BS/ MIN .6 .7 .8 .9 L0 Ll L2 L3 MnO/SiOg INVENTOR. CLARENCE E.JACKSON ATTORNEY SUBMERGED MELT WELDING PROCESS AND COMPOSITION Filed Oct. 24. 1960 Feb. 19, 1963 c. E. JACKSON 4 Sheets-Sheet 3 OON 00v OON -06- 05 zoEwonou 593 545052200 ZOrCWOQZOU INVENTOR. CLARENCE E. JACKSON Syd I 29? ATTORNEY COMMERCIALLY V5 AVAILABLE COMPOSITION 2 TYPE D INVENTIVE .I COMPOSITION u. MnO-SIO TYPE Feb. 19,1963 c. E. JACKSON I 3,078,193

SUBMERGED MELT WELDING PROCESS AND COMPOSITION Filed Oct. 24, 1960 Y 4 Sheets-Sheet 4 I0 20 3O 4O 50 I WELDING VOLTAGE INVENTOR. CLARENCE E. JACKSON A TTORNEY v L. d, i p J, lllnr eo sprains sons tranche v rnocnss ooswostrron ANE Filed (Ber. 24, race, Ear. No. 64,547 '7 or. tes zo This invention relates to submerged melt welding and composition, and more particularly to a work-in-circuit arc welding wherein a consumable metal wire or rod elec trode deposits molten metal beneath a blanket of granular welding composition.

The invention a submerged melt Welding composition consisting essentially of silicate selected from the class consisting of manganese silicate and manganese alumina silicate, in which the ratio of MnO to Si0 is between 0.6 1.0, inclusive, to minimize the amount of such composition needed for eifec'tive welding therewith; said composition containing from a trace to 8% CaF and from a trace to 3.0% EaO to control the ionization potential of the composition by effectively increasing such potential with a decrease in the Bat) content thereof.

in the formulation of granular compositions for submerged-arc weiding, particularly of the MnOSiO and Mn0Al O -Si0 types, an understanding of the problems associated with control over the melting rate of the electrode and consumption of the welding composition is essential. In fact, a frequently used standard of comparison between various types of welding compositions is based upon the ratio of the flux consumption to that of the melting rate of the electrode. Usually the producer having the lowest melt to electrode consumption ratio points to this relationship as making his material more suitable for use than that of a competitive manufacturer exhibiting a non comparable ratio. Directly associated with this standard, is the matter of Welding economics and also satisfactory mechanical characteristics of the metal as deposited.

it. is well known in the welding art that as the ratio of flux consumption to metal deposited by the consumable electrode increases, the cost of the flux utilized in such an operation will increase directly with a comparable increase in said ratio. However, previous to this invention, the welding art has not successfully formulated a welding flux capable of adequately controlling this ratio. All previous approaches readily accepted the particular ratio which accompanied adequate welding performance. Nevertheless, the ever present desire to increase welding economics while at the same time providing satisfactory welds has focused attention upon a new method for controlling the flux consumption-to-electrode melting rate ratio.

Previous to this invention, M110 and SiO content have been held to within welding liux formulation specification limits which provided adequate welding performance while minimizing undesirable spatter, porosity, and erratic arcing. Little attention was given to the effects of Moo and SlOg upon the recovery of manganese and silicon in the weld zone. Investigation has revealed, however, that as consumption of these constituents increases, the recovery of Mn and Si in the weld metal similarly increases. Up until the advent of the present invention, the importance of this relationship has not been generally recognized as an essential factor in th formulation of welding fluxes for submerged-arc welding.

The basic obiect of this invention is to provide a method for adequately controlling the electrode deposition rate over a wide range while being able to independently control the consumption rate.

Another object is to satisfactorily control the ratio of 3,07%,lh3 Patented Feb. l9, W53

flux consumption to consumable welding electrode deposition. 1

Still another object is to provide means for minimizing the presence of manganese and silicon in weld metal by decreasing the ratio of flux consumed to electrode deposited.

A further obiect is to minimize unit weld costs by reducing flux consumption, while at the same time increasing weld metal deposition.

in the drawings:

FIG. 1 is a view in elevation of a submerged arc welding set-up illustrating the invention; and

FIGS. 2-4 are graphical representations.

As shown in FIG. 1, a consumable electrode composed of metal in the form of wire or rod it) is drawn from a reel 12 by a feed roll 1d which is driven by a motor 16, and thereby fed through a contact tube 13 toward the work Ltd to be welded. Such electrode is connected in an arc Welding circuit that includes such work and conductors 22 and 2d connecting a welding power source '26 to the contact tube 18 and work 26 respectively. Granular welding composition 2.8 is delivered to the welding site by gravity through a pipe 3% from a hopper 32 containing a supply of such composition. Relative movement between the work and the electrode til under such composition 28, in the direction of the seam 34 occurs during the welding operation.

TABLE I Ratio, Flux] Electrode Electrode,

Flux,

lbs/min.

Producer 1bs./min.

N0'rn.Welds made at 900 amperes with alternating current 40 volts, and 24 in./min. travel with in. diameter elect'rode. All values calculated to 1000 amperes for comparlson.

Table I indicates typical results obtained with commercial submerged-arc-welding fluxes. It is apparent from such comparative data, that the melting rate of the consumable electrode with several kinds of commercial fluxes will vary from a low of 0.40 lbs/min. to a high of 0.48 lb./min. at 1000 amperes welding current. While at the same time, the flux consumption for this group of data ranged from 0.76 to 1.10 lbs/min; thus, yielding a flux-to-electrode ratio range of 1.7 to 2.6.

The variation in this ratio coupled with the-excellent performance characteristics of the MnO-SiO and MnO-Al O -SiO type of compositions has lent itself to an investigation of the development of submerged-arc welding compositions exhibiting lower flux-to-electrode ratios than heretofore obtainable.

As a way toward lowering the flux-to-electrode ratio, it was sought to increase the melting rate of the electrode and also to decrease the consumption of the flux as controlled by the formulation of the welding composition.

In the past, little attention has been paid to the content of incidental CaO, MgO, and Boo in the commercial manufacture of sumberged-arc welding fluxes of the MnO-Si0 type and the MnO-Al O SiO types. A comparison of such commercially available fluxes is made in Table ll. Here considerable CaO, together with B210 and other incidental constituents is present. Hence, it was sought to carefully study the influence of these constituents upon the entire welding operation.

TABLE II Typical Compositions for Several Commercial Submerged-Arc Fluxes Percent Present Constituent K L M N O 43.16 40. 36 39. 36 42. 11 28.0 0.12 ND 0.00 0. 25 0.5 1.01 0.70 1. 18 1. 80 1. 80 0. 21 ND 0. 23 0.20 0.3 ND ND 0. 87 0. 20 0. 3 5. 16 4. S0 5. 75 5.00 5.0 0. 92 1.57 2.73 1. 25 0.75 0.03 0. 01 0. 02 0. 02 0.02 0.10 0.02 0.05 0.03 0. 03

N DNot determined.

FIG. 2 presents the results of a number of weld tests performed with various flux compositions of the MnO- SiO; type. The range of B210 present varied from substantially 0 to 3.0 percent. -Iere, most dramatically, is revealed that there exists a direct correlation between the melting rate of the consumable electrode to that of the amount of BaO present in the composition. It is apparent that as the amount of B210 present is increased the melting rate of the electrode decreases. Furthermore, with the proper selection of raw materials, the electrode melting rate can be controlled from over 0.50 lb./min. 3

down to 0.40 lb./min. Since it is desirable to obtain maximum electrode deposition, the subsequent welding compositions tested were formulated to provide a deposition rate of at least 0.50 lb./min.

TABLE III Selected Hearts of MnOSiO Type of Submerged-Arc Composition I-lcat Raw Materials 1 2 3 4 5 6 7 I 8 MangancseOreLb nn 8.4 8.2 8.0 8.2 10.0 8.8 9.2' 8.4 Silioa,Lbs 5.5 5.7 5.9 5.7 4. 1 5.1 4.7 5.5 CalciumFluoride,Lbs 1.1 1.1 1.1 1.1 1.1 1.1 1.1 1.1

1 Manganese Carbonate; all other heats made with manganese dioxide ore.

fl able III, discloses the various types of weldiinjcornpositio'n's' considered and studied" Whose raw materials 75 were so selected as to minimize the B210 and CaO content. Subsequently, the actual welding tests performed (Table IV) indicated that the electrode melting rate for these welding compositions Was higher than any material previously studied. It is apparent that the BaO and other incidental constituents such as CaO and alkaline elements which are present in commercial welding fluxes are critical constituents in the formulation of the welding flux. Further, such comparative data revealed that control over the electrode melting rate could be satisfactorily controlled by adjusting the content of H210 and other incidental constituents.

Hence', an understanding of the factors relative to increasing the melting rate of the electrode thus provides asolution to the first phase for formulating a welding composition with a low flux-to-electrode melting ratio.

TABLE IV Results of Welding Tests With Compositions in Table III Ratio, Heat No. Flux Electrode Flux/Electrodc T twelding tests for reference used some welding procedure as given in .1 c 1.

Further consideration of the data in Table IV obtained from the Welding tests indicates that the range of the flux consumed varied from 0.70 to 0.90 lb./min. It is apparent that the flux consumption is not dependent upon the B210 and other incidental constituent contents. However, it is important to determine the factors which relate to flu); consumption since the fluX-to-electrode ratio varied from 1.3 to 2.0 lbs/min. The influence of the 13210 in the composition appears not to be significant upon flux consumption; but instead, the fluxconsumption is a function of the principal constituents present; namely, the amount M and SiO Since the compositions examined in Table II were essentially binary in character, any factor dependent upon the composition may be related to the amount of either constituent present or more precisely to the ratio of these components.

Consequently, the MnO/Si0 ratio was examined and its effects upon flux consumption indicated in FIG. 2. Unexpectantly, the flux consumption was observed to be related to the MnO/SiO wherein it Was found that consumption increases rapidly beyond a Mno/Si0 ratio of approximately 1. The inherent physical characteristics such as melting temperature, specific heat, electrical conductivity, and ionization behavior of these principal constituents have a strong influence upon flux consumption.

Hence, the second phase relative to controlling flux consumption provides the method by which a desired flux formulation leading to a controlled flux-to-electrode ratio can be obtained.

With an understanding of the mechanism necessary for controlling the melting rate of the electrode and the welding flux consumption, the formulation of a Welding flux capable of providing any desired ratio flux consumption to electrode melting rate is possible.

Thewelding art has long searched for a welding flux on the above findings, must have a' low BaO and impurity content together with an MnO/SiO ratio of less than 1.

The following is an actual formulation of a welding Tests over a range of welding currents (from 400 to 1550 amperes) made with the newly formulated flux as compared with a well known commercially available flux shown in Table V revealed that:

(1) The electrode melting for the new composition was higher in all cases.

(2) The fiux consumption was lower in all cases which resulted in a large reduction in the flux consumption to electrode melting rate ratio.

TABLE V Range Constituents Present S10 -46 M110 24-46 CaF Trace-8 FeO 2 max. A1 0 1 max. CaO 3 max. TiO 1 max. BaO Trace-3 N'a O 0.5 max. K 0 0.5 max. MgO 1 max.

M110 Ratio ran e 0.6 to 1.0

The following is an actual formulation of a welding flux of the manganese alumina silicate type:

Percent MnO 30.0 A1 0 21.8 S10 39.6 021% 5.0 MgO 0.1 Ca() 0.5 Bat) 0.1 FeO 1.5 TiO 0.7 K 0 0.5 0.1 PbO 0.1 100.0

Welding Tests Comparing Commercial Submerged-Arc Flux With New Composition Welding Procedure Melting Rate-Lbs/Min.

Flux

Current, Voltage, Travel, Electrode Flux Ratio, Flux/ Amperes Volts i.p.m. Electrode Commercial.... 40 24 0. 358 0. 880 2. eW.. 40 2-1 0. 450 O. 670 1. 45 Commerc 35 2d 0. 386 0. 630 1. 63 New 35 24 0. 400 0. 485 l. 05 C0mmercial. 30 24 0. 419 O. 422 1.00 New 90 30 24 0. 480 0. 330 O. 69 Commercial..- 41 11 0. 730 0. 800 1. 21 41 ll 0. 980 0. 990 1. 00 40 12. 5 0. 560 0. 040 1. 68 40 12. 5 0. 090 0.675 0. 98 30 20 0. 250 0. 348 1. 38 30 20 0. 293 0. 304 1.04 30 20 0. 234 0. 383 1. 63 New 30 20 0. 273 0. 298 1. 09 Commercial. 30 20 0. 327 0. 410 1. 25 New 30 20 0. 386 0. 261 0. 67 Commercia1. 26 20 0. 180 0.255 1. 42 New 26 20 0. 188 0.210 1. 15

FIGURE 4 represents a trace of data tabulated in Table V and further emphasizes the increase (ranging from 20 to 30 percent) of the electrode milling rate of the new flux as compared with prior commercially available fiux. With the increase in the electrode melt rate there exists a decrease in the flux consumption equal to from 15 to 30 percent for that of the new formulation over that for the commercially available flux as shown in FIG. 5.

As a result of this phenomenon, the flux consumption to electrode deposition ratio is drastically reduced for the new composition. For example, as shown in Table V, at 900 amperes, 40 volts, 24 in./min. travel, the flux consumption to electrode deposition ratio was decreased from 2.5 for the commercially available material to 1.45 for that of the new formulation.

Based upon this information, it was found that the constituent range indicated below provides a sufficient degree of flexibility necessary for tailoring a formulation to meet a given need. Also the preferred MnO to SiO ratio, together with the BaO range, aids in controlling both the melting rate of the electrode and the flux consumption rate.

As has been pointed out above with respect to the manganese silicate type, the manganese alumina silicate type Welds carried out at 900- amperes, 40 volts, 24 iii/min, the flux consumption to electrode deposition ratio was decreased to 1.2. The addition of 2% of BaO to the above composition reduced the electrode melting rate by over 15 percent so that the flux consumption to electrode eposition was 1.50.

rom the foregoing it will be clear to those skilled in the art that the invention includes the following novel features and advantages:

A fused submerged-arc Welding flux of a class composed substantially of M and 510 so formulated that the electrode deposition rate is relatively independent of the flux consumption rate;

A fused submerged-arc welding flux of a class composed substantially of MnOAl O -SiO so formulated that the electrode deposition rate is relatively independent of the flux consumption rate;

A fused submerged-arc welding flux wherein the range of the MnO-SiO ratio varies from 0.6 to 1.0 while the amount of 3210 present varies from substantially 0 to 3 percent;

A fused submerged-arc welding flux whose BaO content is preferably less than 0.25 percent to permit adequate control over the melting rate of the consumable electrode;

A fused submerged-arc welding flux wherein sufiicient control over the MnO-SiO ratio provides a method for regulating the flux consumption rate in a Welding operation; and

A fused submerged-arc welding composition wherein a low BaO constituency in combination with a controlled MnO-Si0 ratio provides a means for obtaining maximum electrode deposition with minimum flux consumption.

What is claimed is:

1. A submerged melt welding composition composed of 42.0 percent MnO, 45.0 percent SiO 6.9 percent CaF 0.3 percent MgO, 1.2 percent CaO, 0.1 percent BaO, 2.0 percent A1 0 1.5 percent FeO, 0.1 percent TiO 0.4 percent K 0, 0.4 percent Na O, and 0.1 percent PbO.

2. A submerged melt welding composition composed of 40-46 percent SiO 24-46 percent MnO, 4-8 per cent CaF 2% (max.) FeO, 1% (max.) A1 0 3% (mars) (3210, 1% (max.) TiO 0-3% 13210, 0.5% (max.) Na O, 0.5% (m-ax.) K 0, 1% of M110 to Si0 falls between 0.6 and 1.0, inclusive.

3. Method of obtaining maximum electrode deposition with minimum flux consumption in work-in-circuit submerged melt welding with a consumable metal Wire or rod constituting such electrode, which comprises blanketing the operation in a fused submerged melt welding composition as defined by claim 2 composed mainly of 30 2,043,960

S10 and MnO having a relatively low B-aO constituency of less than 3% in combination With a controlled MnO- SiO; ratio of between 0.6 and 1.0.

(max.) MgO; in which the ratio- 4. Method of submerged melt welding which comprises feeding a ferrousmetal electrode toward steel work while supplying welding current thereto at a voltage sufiicient to cause the end ofsaid electrode to melt under a blanket of granular fused welding composition as defined by claim 2, whereby such welding is accomplished at a substantially decreased composition to electrode deposition ratio, and at a substantially increased electrode melting-rate.

5. Submergedmelt Weldingwhich comprises feeding a consumable metal-electrodetoward the work-in-circuit to be weldedund-er-a-blanket of-s-ubmerged meltwelding composition consisting of-atused-fiux as defined by claim 2, whereby the deposition rate of such electrode is relatively independent of the consumption rate of such flux.

6. Submerged melt welding asdefined'by claim 5, in which'theratio of MnO to'SiOg varies from 0:6 to 1.0,

and theflux' contains'B'aO fronra tr'ace'up" to 3% of the composition to increase the deposition rate by a decreasing in the B210 content thereof.

7. A submerged melt welding compositioncomposed of'30.0% MnO, 21.8% A1 0 39.6% SiO 5.0% CaF- 0.1% MgO, 0.5% CaO, 0.1% Red), 1.5% FeO, 0 .7% Ti0 0.5% K 0, 0.1% M 0 and 0.1% PbO.

References Cited in the file of this patent UNITED STATES PATENTS Jones et al. June 9, 1936' 

2. A SUBMERGED MELT WELDING COMPOSITIONG COMPOSED OF 40-46 PERCENT SIO2, 24-46 PERCENT MNO, 4-8 PERCENT CAF2, 2% (MAX.) FEO, 1% (MAX.) AL2O3, 3% (MAX.) CAO, 1% (MAX.) TIO2, 0-3% BAO, 0.5 (MAX.) NA2O, 0.5% (MAX.) K2O, 1% (MAX) MGO; IN WHICH THE RATIO OF MNO TO SIO2 FALLS BETWEEN 0.6 AND 1.0, INCLUSIVE. 